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Tutorial Shaft Systems

This tutorial shows how to model and analyze a two-stage gearbox using MESYS shaft calculation software. Key steps include: 1) Defining three parallel shafts with cylinders, bearings, and gears as system components. 2) Connecting gears between shafts to model the gearbox transmission. 3) Positioning the shafts based on gear pair connections and resolving collisions. 4) Running calculations to analyze gear and bearing safety factors and minimum life under load conditions.

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Hamidu
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Available Formats
Download as PDF, TXT or read online on Scribd
57 views

Tutorial Shaft Systems

This tutorial shows how to model and analyze a two-stage gearbox using MESYS shaft calculation software. Key steps include: 1) Defining three parallel shafts with cylinders, bearings, and gears as system components. 2) Connecting gears between shafts to model the gearbox transmission. 3) Positioning the shafts based on gear pair connections and resolving collisions. 4) Running calculations to analyze gear and bearing safety factors and minimum life under load conditions.

Uploaded by

Hamidu
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Tutorial: Calculation of a two stage

gearbox
This tutorial shows the usage of MESYS shaft calculation with systems of parallel shafts. A two stage
gearbox is defined using the program. Please start with the tutorial for shaft calculation to see how
to introduce geometry and supports for single shafts.

System Data

We don’t need to change anything on the first page for system data.
Defining Shafts
For systems of parallel shafts groups have to be used. With a right mouse
click on ‘Shafts’ in the system tree three groups can be added.

The groups can be given a name on the page for the group:

Now for each group we add a shaft and name them ‘shaft 1’ to ‘shaft 3’.

For each shaft we add a geometry as a cylinder with length 120 and
diameters 20 for ‘Shaft 1’, with length 100 and diameter 25 for ‘Shaft2’
and length 120 and diameter 30 for ‘Shaft3’.

For the shafts we add the following elements:

Shaft Element Name Position Parameters


Shaft1 Coupling Input 10 Mx = 20Nm
Gear G1 55 mn=1, =20, b=20, z=25
Rolling bearing B1 30 Deep groove ball bearing 6204
Rolling bearing B2 110 Deep groove ball bearing 6204
Shaft2 Gear G2 35 mn=1, =20, b=20, z=60
Gear G3 65 mn=1.5, =20, b=25, z=20
Rolling bearing B3 10 Deep groove ball bearing 6205
Rolling Bearing B4 90 Deep groove ball bearing 6205
Shaft3 Gear G4 65 mn=1.5, =20, b=25, z=50
Rolling bearing B5 10 Deep groove ball bearing 6206
Rolling bearing B6 90 Deep groove ball bearing 6206
Reaction coupling Output 110
Now the shaft should look like the following images:

Defining gear connections


As the next step connections are defined between the gears. For this select ‘Gear connections’ in the
system tree, click on ‘Cylindrical gear pairs’ and add a connection using the -button on the right.

Now select the shafts and gears which should be connected. Connect G1-G2 for the first pair, then
add a second pair and connect G3-G4. Circumferential backlash and gear mesh stiffness can be
changed here. It is not needed to enter the center distance as it will be calculated later. The
calculation program for the gear strength calculation can be selected if available.
Define positioning
The next step is to define the positioning of the shafts. For this select ‘Positioning’ in the system tree.

Add two constraints using the -button on the right. Several options for positioning are available.
Select ‘Group according gear pair’ and position ‘Group2’ with pair ‘G1-G2’ and ‘Group3’ with pair
‘G3-G4’. The angle could be changed, we just leave it to 0° for this example, getting a vertical
orientation of all shafts.

Now click on ‘Shafts’ in the system tree and choose the x-y-plane for the view:
We see that there are collisions between the bearings. We go back to ‘Gear connections’ and change
module for pair ‘G1-G2’ to 1.25 and to 1.75 for ‘G3-G4’. Afterwards the space between the bearings
is small, but we don’t have any collisions:

Running the calculation


Before running the calculation we have to define the speed
for the system. Enter a speed of 1000rpm for ‘Shaft1’.

For all other shafts the flag behind the input of speed
should not be set as the speed is calculated by the
program.

After running the calculation the results overview should look similar to the following:

The safety factors for the gears depend on the selected program for gear calculations. We also did
not enter any details for the gear calculations. Minimum bearing life is 5200h, static bearing safety is
3.3. Therefore bearings could be ok, dependent on the needs for life. Minimum gear safety is 1.14 for
the flank and 3 for the root stresses, so gears should also be ok.

This can now be used to detail the shaft geometry and optimize the gears.

Gear calculations
For gear calculations the ‘Required Life’ on page ‘System’ should be defined. Also either ‘Consider
gears as stiffness’ should be set which results in an automatic increase of shaft diameter according to
the gears, or you should consider the gear stiffness in the shaft geometry yourself.
The gear calculation can be opened by selecting the gear pair in the system tree.
Dependent on the gear calculation program it is opened within the shaft
calculation program or as an extra window. Gear parameters can be changed and
are read back on closing the gear calculation.

On the page ‘Gear connections’ the torque for each gear is shown and its safety factors. Selecting
‘Cylindrical gear pairs’ an overview for gear pair data is shown in a table.

Graphics for gear pairs


Two graphics for gear pairs are available so far. The line load and the gap width.
The gap width shows the gap between the flank if the contact would be just on one point. So in this
case a flank line correction of 2m could be made. These diagrams are made with the setting
‘Consider gears as stiffness’ set. Gear mesh stiffness, shaft and bearing stiffness have an influence to
these diagrams. But also manufacturing errors and housing stiffness have an influence on the real
gearbox.

Considering load spectra


Load spectra are added easily to the system. Go to the ‘System’ page, select ‘Consider load spectrum’
and then go to the new page ‘Load spectrum’:

Press the right mouse button and select ‘Hide All’. Then press the right mouse button again and
select ‘Shaft1’->’General’->n and ‘Shaft1’->”Input’->’Mx’. Then add two lines using the -button on
the bottom:
For a simple load spectrum we add a first case with frequency 0.7, speed 1000rpm and torque 20Nm
and a second load case with frequency 0.3, speed 500 and torque 30.

Now all gears and bearing are calculated using the load spectrum. On the ‘Gear connections’ page we
see the torques for each load case and the safety factors for the whole spectrum:

An additional graphics for the gear connections show the line load for all load cases:

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